US20120153730A1 - Interleaved llc converter employing active balancing - Google Patents
Interleaved llc converter employing active balancing Download PDFInfo
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- US20120153730A1 US20120153730A1 US13/218,938 US201113218938A US2012153730A1 US 20120153730 A1 US20120153730 A1 US 20120153730A1 US 201113218938 A US201113218938 A US 201113218938A US 2012153730 A1 US2012153730 A1 US 2012153730A1
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M3/00—Conversion of dc power input into dc power output
- H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
- H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
- H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
- H02M3/285—Single converters with a plurality of output stages connected in parallel
Abstract
Description
- This application claims the benefit of U.S. Provisional Application Ser. No. 61/424,351, filed by Rick L. Barnett, et al., on Dec. 17, 2010, entitled “INTERLEAVED LLC CONVERTER USING ACTIVE BALANCING,” which is incorporated herein by reference in its entirety.
- The invention is directed, in general, to an inductor-inductor-capacitor (“LLC”) power converter, and more specifically, to a plurality of interleaved LLC power converters.
- LLC power converters are becoming an important part of power conversion systems. LLC power converters have a number of advantages when compared to other power converters. These advantages may include high efficiency, zero voltage switching on primary switches across the entire output load range, and lower electromagnetic emissions. LLC power converters can also operate at higher switching frequencies than many other forms of power converters, which can in turn lower the size of magnetics in LLC power converters.
- In some applications, LLC power converters may be interleaved. Interleaving power converter stages can provide additional output power capability while minimizing the input and output filtering capacitance. However, disadvantages can also arise when interleaving LLC power converters. One disadvantage when interleaving LLC power converters is the inability to current share between the power stage channels when the resonant components are not well matched. The mismatches may result, for example, from differences in the values caused by manufacturing or temperature variations.
- In one aspect, the disclosure provides an interleaved LLC converter. In one embodiment, the LLC converter includes: (1) a plurality of LLC power channels, with each of the plurality having an independent power input and (2) a compensation controller configured to actively adjust the independent power inputs to substantially match output voltage and current levels for a given load condition and a common operating frequency, of the plurality of LLC power channels.
- In yet another aspect, a method of operating a LLC converter having a first and a second LLC power channel is provided. In one embodiment the method includes: (1) generating, at a first LLC power stage of the first LLC power channel, a first DC power output from a first independent power input, (2) generating, at a second LLC power stage of the second LLC power channel, a second DC power output from a second independent power input, (3) actively adjusting the first and second power inputs to substantially match output voltage and current levels for a given load condition and a common operating frequency, between the first and the second LLC power stages and (4) interleaving the first DC power output and the second DC power output to provide output power for the LLC converter.
- In still another aspect, the disclosure provides a power supply. In one embodiment the power supply includes: (1) a first LLC power channel having a first LLC power stage and a first dedicated power source configured to generate a first independent power input for the first LLC power stage, (2) a second LLC power channel having a second LLC power stage and a second dedicated power source configured to generate a second independent power input for the second LLC power stage, wherein outputs of the first and the second LLC power stages are interleaved and (3) a compensation controller configured to actively adjust the first and the second independent power inputs to substantially match output voltage and current levels for a given load condition and a common operating frequency of the first and the second LLC power stages.
- Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
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FIG. 1 is an illustration of a block diagram of an embodiment of an interleaved LLC power converter constructed according to the principles of the disclosure; -
FIG. 2 is an illustration of a schematic diagram of another embodiment of an interleaved LLC power converter constructed according to the principles of the disclosure; -
FIG. 3 illustrates a graph of an example of an output voltage of two interleaved LLC power converters constructed according to the principles of the disclosure; -
FIG. 4 is an illustration of a block diagram of yet another embodiment of an LLC power converter constructed according to the principles of the disclosure; -
FIG. 5 is an illustration of a block diagram of still another embodiment of an LLC power converter constructed according to the principles of the disclosure; and -
FIG. 6 is an illustration of a flow diagram of an embodiment of a method of operating an interleaved LLC power converter carried out according to the principles of the disclosure. - The disclosure describes the use of an active balance technique for multiple power channels of an interleaved LLC converter. The active balance technique may compensate for the relative tolerances between the multiple interleaved power stage channels by actively modulating independent power inputs for the LLC power stages of the power channels until the plant output voltages and currents are matched for the given operating condition. The independent power inputs are dedicated power inputs for each particular LLC power stage. In one embodiment, the independent power input is a dedicated voltage level for each LLC power stage. The independent power input may be modulated by varying the output of existing pre-regulators of the power channels. As such, in some embodiments, additional regulation stages are not required.
- The active balance technique disclosed herein can compensate for variations in the DC gain associated with each channel due to variations of the resonant components. This active balancing technique will compensate for unequal sharing between the channels caused by differences in values of the resonant components, temperature variations, operating conditions, and other factors which may cause the channels to be dissimilar. Accordingly, the active balance technique actively adjusts the independent power inputs of each LLC power stage to substantially match output voltage and current levels for a given load condition and a common operating frequency. The pre-regulator output voltages (e.g., PFCs) are adjusted by controls to levels to achieve current/power balance in the LLC stages. The levels adjusted to most likely are not equal. The active balance technique may also control the pre-regulator output currents to be equal. In this case, the pre-regulator output voltages are floated or allowed to fly in order to have balanced LLC's. Thus, the active balance technique actively adjusts (or margins) the output voltage of each pre-regulator to actively balance the currents and voltage of the LLC stages. Adjusting may be performed by moving the pre-regulator output up and down from a standard operating point.
- The active balance technique may employ standard, low cost resonant components and does not necessarily require an extra pre-regulator stage. Standard resonant components are typically less expensive than tight tolerance components. Additionally, having no extra pre-regulator stages may result in greater efficiency. The disclosed active balancing technique is applicable, but not limited to, high efficiency rectifiers with nominal output voltages of 12V & 48V and is well suited for low output voltage and high current applications.
- In an interleaved LLC converter, the phase angles between the multiple power channels are appropriately shifted to minimize current ripple in the filter capacitor across Vo of the converter. For an interleaved LLC converter having two channels, the phase of the second channel is shifted by ninety degrees. When additional channels are added, the phase angle between each of the channels of the interleaved LLC converter changes. For example, for three channels, each channel is shifted by sixty degrees with respect to the previous one. “N” channels would mean each channel is shifted by 180/N degrees with respect to the previous one.
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FIG. 1 is an illustration of a block diagram of an embodiment of an interleavedLLC power converter 100 constructed according to the principles of the disclosure. Theconverter 100 may be an AC to DC converter that receives an AC input and generates a DC output. Theconverter 100 includes a plurality of LLC power stages with each of the plurality having a power input that is independent of a power input of the remaining plurality of LLC power stages. Thus, each LLC power stage receives an independent power input. InFIG. 1 , three LLC power stages are illustrated. However, one skilled in the art will understand that theconverter 100 may include more than three LLC power stages as represented by the dashed lines. Additionally, one skilled in the art will understand that theLLC power converter 100 may include additional components that are not illustrated or discussed but are typically included in conventional LLC converters. - The
converter 100 is configured to provide DC power to aload 180. Theconverter 100 includes threepower channels power channels Power channel 110 includespower source 114 andLLC 118.Power channel 120 includespower source 124,LLC2 128, andpower channel 130 includespower source 134,LLC3 138. The power source for each power stage channel generates a DC output that is provided as an independent power input for the corresponding LLC power stage. Each generated DC output of the dedicated power sources is independent of generated outputs from the power sources of the other power channels. Thus, each generated output is an independent DC output that provides a dedicated DC power input for each of the corresponding LLC power stages. For example,power source 114 generates a DC power output that provides an independent power input forLLC 118. - As noted above, each
power source power stages LLC 118,LLC 128 andLLC 138. In some embodiments, thepower sources power sources power sources - The DC power generated by a single or shared bridge rectifier may be supplied to a pre-regulator of each power source. As such, each of the
power sources - Each
LLC power stage load 180. - The
compensation controller 170 is configured to actively adjust the independent power inputs of eachLLC power stage compensation controller 170 may be a dedicated computing device that is constructed to substantially match the output voltage and current levels for a given load condition and a common operating frequency, of the LLC power stages 118, 128, 138. To perform the described functions, thecompensation controller 170 may be embodied as a series of operating instructions stored on a non-transitory computer-readable medium that directs the operation of a processor when initiated thereby. Accordingly, thecompensation controller 170 may include a processor and an associated memory. In one embodiment, thecompensation controller 170 may be a dedicated computing device including the necessary circuitry (including a processor and memory) and/or software to perform the described functions. Thecompensation controller 170 may be a software/firmware module that is deployed or integrated within a computing device that is configured to perform other functions, such as, for theconverter 100. - In one embodiment, the
compensation controller 170 is configured to actively adjust the independent power inputs by modulating at least one of thededicated power sources power sources compensation controller 170 may modulate a power source by controlling a power switch of the power source. In one embodiment, thecompensation controller 170 may modify the duty cycle of a power source. For example, each of thepower sources compensation controller 170 may modify the duty cycle of the power switch to control the DC power output of thepower sources compensation controller 170 may modulate a power source based on an input current of the LLC power stages 118, 128, 138. In some embodiments, analog hardware controls may be employed to perform the functions of thecompensation controller 170. - In another embodiment, the
compensation controller 170 may by configured to actively adjust the independent power inputs by regulating input currents of the LLC power stages 118, 128, 138, to the same or at least substantially the same level. The input currents may be regulated by a closed feedback loop coupled to thecompensation controller 170.FIG. 5 illustrates an embodiment of LLC converters that actively balance output voltage and current levels for a given load condition and a common operating frequency by regulating the input currents of LLC power stages. -
FIG. 2 is an illustration of a block diagram of another embodiment of an interleavedLLC power converter 200 constructed according to the principles of the disclosure. TheLLC power converter 200 is an example of a converter that actively balances DC gain by modulating a power input for each LLC stage. Theconverter 200 includes a converterDC power source 210, afirst power channel 220, asecond power channel 230, acompensation controller 240, aLLC controller 250 and anoutput filter capacitor 260. - The
converter power source 210 is configured to receive AC power and generate DC power. InFIG. 2 , theconverter power source 210 is a full wave bridge rectifier that receives AC power, L1 and L2 (i.e.,line 1 and line 2) and generates DC power that is provided to both thefirst power channel 220 and thesecond power channel 230. In some embodiments, theconverter power source 210 may be a bridgeless rectifier. In other embodiments, a DC input may be received and a DC/DC stage employed to provide power to thefirst power channel 220 and thesecond power channel 230. - The
first power channel 220 includes a firstdedicated power source 222, a firstDC link capacitor 224 and aLLC power stage 226. The firstdedicated power source 222 receives the DC power from theconverter power source 210 and conditions the DC power to provide to the firstDC link capacitor 224. In the illustrated embodiment, the firstdedicated power source 222 is a PFC circuit for thefirst power channel 220. TheDC link capacitor 224 links the first stage of thepower channel 220, the PFC stage, to the second stage of thepower channel 220, theLLC power stage 226. TheLLC power stage 226 receives the conditioned DC output power and generates a first channel output power. The firstdedicated power source 222, theDC link capacitor 224 and theLLC power stage 226 may be conventional components. Thesecond power channel 230 includes a seconddedicated power source 232, a secondDC link capacitor 234 and aLLC power stage 236. Each of these components operate similarly as the corresponding components of thefirst power channel 220 described above. - The
compensation controller 240 is configured to actively adjust the independent power inputs to the LLC power stages 226, 236, to substantially match output voltage and current levels for a given load condition and a common operating frequency, thereof. By adjusting the independent power inputs, thecompensation controller 240 can compensate for differences in values of the resonant components of the LLC power stages 226, 236, temperature variations, operating conditions and other factors which may cause the first andsecond power channels first power channel 220 and thesecond power channel 230 allows employing standard, lower cost resonant components compared to more expensive resonant components that are manufactured with tight tolerances. - The
compensation controller 240 includes afirst modulator 242, asecond modulator 244 and balancingcircuitry 245. Thefirst modulator 242 and thesecond modulator 244 provide independent control loops for the firstdedicated power source 222 and the seconddedicated power source 232, respectively, to modulate the magnitude of the independent and dedicated power sources of eachpower channel first modulator 242 and thesecond modulator 244 generate a duty cycle (i.e., dl and d2 inFIG. 2 ) for the respective switches of the firstdedicated power source 222 and the seconddedicated power source 232 to control the modulation thereof. Each of themodulators circuitry 245 to determine the duty cycles d1, d2. Additionally, bothmodulators modulators - For example, the
first modulator 242 receives the input current Ibst1 and the input voltage V from the 210. Thefirst modulator 242 also receives the balancing input from balancingcircuitry 245 and the output voltage Vbst1 from the firstdedicated power source 222. Thefirst modulator 242 compares the input power parameters, Ibst1 and V, to the output voltage Vbst1 and the desired output current represented by the balancing input. Based on the comparison, themodulator 242 determines the needed duty cycle for the firstdedicated power source 222 to generate the desired output current that is provided to theLLC power stage 226. Themodulator 244 operates similarly to generate the duty cycle d2 employing the operating parameters of thesecond power channel 230. The firstdedicated power source 222 and the seconddedicated power source 232 employ the duty cycles dl, d2, to provide an equal or at least substantially equal Ib1 and Ib2. The balancing inputs generated by the balancingcircuitry 245 represent the desired input current (i.e., desired Ib1 and Ib2). Ibst1, Ibst2, V, Vbst1, Vbst2 and the communication signal of theLLC controller 250 are all used in normal operation of a conventional interleaved LLC power converter and are illustrated for clarity inFIG. 2 . Unlike conventional interleaved LLC power converters, the interleavedLLC power converter 200 compares Ib1 to Ib2, then based on this comparison, the magnitude of Vbst1 and Vbst2 are margined or adjusted until the LLC power stages 226, 236, draw equal currents. - The balancing
circuitry 245 includes three summers, 246, 247, 248, and anaverager 249. Thefirst summer 246 receives the input currents Ib1 and Ib2, adds these currents together and provides the total value of the two currents Ib1, Ib2, to theaverager 249. Theaverager 249 is a gain stage of 0.5 that is configured to divide the total value of the two currents Ib1, Ib2, to generate an average current value. Thesummer 247 determines the difference between the average current value and Ib1 and provides this first balancing input to themodulator 242. Thesummer 248 similarly determines the difference between the average current value and Ib2 and provides this second balancing input to themodulator 244. As noted above, themodulators - The
LLC controller 250 generates control signals for the LLC power stages 226, 236, based on feedback signals (i.e., output power of theconverter 200, Vo and Io) at theoutput filter capacitor 250. As illustrated inFIG. 2 , the control signals may be frequency control signals for the LLC power stages 226, 236. For interleaving, the LLC power stages 226, 236, are run at the same frequency with one phase shifted by 90 degrees with respect to the other. Both theLLC controller 250 and theoutput filter capacitor 260 may be conventional components that are typically employed with LLC converters. -
FIG. 3 illustrates a graph of an example of output voltage characteristics of two LLC converters constructed according to the principles of the disclosure. The graph ofFIG. 3 represents matching or substantially matching output voltage and current levels for a given load condition and a common operating frequency of LLC stages, such as in, for example, theLLC converter 200 ofFIG. 2 . The y-axis of the graph is the output voltage of the LLC converter and the x-axis is the load resistance. InFIG. 3 , the graph represents two output voltage characteristic curves Vo1 and Vo2, of the two LLC power channels. By dynamically modulating the voltage magnitude of input sources of each LLC power stage (i.e., an LLC DC/DC output stage), the characteristic curves of each LLC power stage can be lined up such that the programmed output voltage (and therefore output currents) remain aligned and balanced as load resistance condition changes. The characteristic curves for the two voltages Vo1 and Vo2 are illustrated with L and C tank values at the extremes of tolerance bands, frequency fixed at 143 kHz and a load resistance of2.95. The independent input voltages, Vbst1 and Vbst2, for the LLC power stages are adjusted to 419 volts and 405 volts respectively, resulting in characteristic curves that intersect at 2.95 ohms. The paralleled outputs of the two LLC power stages will then share output current and power equally at this load condition. The values of the various components used for the simulation to generate the graph ofFIG. 3 are provided therein. -
FIG. 4 is an illustration of a block diagram of yet another embodiment of anLLC power converter 400 constructed according to the principles of the disclosure. As with theLLC converter 200, theLLC power converter 400 includes two power channels with similar components that may operate as described with respect toFIG. 2 . Additionally, theLLC converter 400 includes acompensation controller 405.FIG. 4 provides detail on the relevant control loops of the firstdedicated power source 222 and the seconddedicated power source 232. Thecompensation controller 405 includes areference voltage generator 410, a firstchannel voltage compensator 420, a secondchannel voltage compensator 430, a firstchannel feedback circuit 440, a secondchannel feedback circuit 450 and acurrent balance controller 460. Thereference voltage generator 410 is configured to receive a reference voltage having a desired value and corrected current signal. The reference voltage may be, for example, the value that you want Vbst1 programmed to be. It could also be a scaled representation of the desired value. Thereference voltage generator 410 includes afirst summer 412 and asecond summer 414 that receive the corrected current signal and the reference voltage and provide therefrom a reference voltage for thefirst channel 420 and thesecond channel 430. The firstchannel voltage compensator 420 includes asummer 422 andcircuitry 424. Thesummer 422 combines the first reference voltage with a first voltage feedback signal from the firstchannel feedback circuit 440. From the combination, thesummer 422 provides a first voltage error signal. Thefirst channel circuitry 424 receives the first voltage error signal and generates a control signal for thededicated power source 222. The firstchannel feedback circuit 440 senses the DC output voltage Vbst1 of thededicated power source 222. The secondchannel voltage generator 430 includes asummer 432 andsecond channel circuitry 434. The secondchannel voltage compensator 430 and the secondchannel feedback circuit 450 perform similarly to the firstchannel voltage compensator 420 and the firstchannel feedback circuit 440 with respect to thesecond LLC channel 230. - The
current corrector 460 includes afeedback circuit 462 and afeedback circuit 464 that provide the sensed output currents, I1 and 12, of thededicated power sources summer 466 of thecurrent controller 460. The currents I1 and may be sensed at various locations associated with thededicated power sources summer 466 generates a current error signal is provided tocurrent balance compensation 468 of thecurrent controller 460. Thecurrent balance compensation 468 provides the corrected current signal that is provided to thereference voltage generator 410. -
FIG. 5 is an illustration of a block diagram of still another embodiment of anLLC power converter 500 constructed according to the principles of the disclosure. As with theLLC power converter 400, theLLC power converter 500 includes similar components to theLLC power converter 200. These components are similarly denoted inFIG. 5 . Additionally, theLLC converter 500 includes acompensation controller 540 that is configured to regulate input currents of theLLC power channels compensation controller 540 includes afirst channel summer 542, acurrent feedback circuit 544 andcurrent compensation 546. Thefirst channel summer 542 receives a reference current and a sensed current of thededicated power source 222. Thefirst channel summer 542 compares the sensed current to the reference current to generate a current error signal that is provided to thecurrent compensation 546. Therefrom, thecurrent compensation network 546 provides a control signal for thededicated power source 222, so that I1 is controlled. - The
compensation controller 540 also includes similar components that are configured to similarly provide a control signal for the seconddedicated power source 232. These components include asecond channel summer 543, acurrent feedback circuit 545 andcurrent compensation 547. In this embodiment, thecompensation controller 540 regulates the input current to the LLC power stages 226 and 236 to equal levels. The input voltages for the LLC power stages 226 and 236, however, are unregulated and will float to where needed in order to accommodate the programmed I1 and 12. -
FIG. 6 is a flow diagram of an embodiment of amethod 600 of operating an interleaved LLC power converter carried out according to the principles of the disclosure. The method begins in astep 605. - In a step 610, a first independent power input and a second independent power input are received from a first dedicated power source and a second dedicated power source, respectively. A first DC power output and a second DC power output are generated at a first and second LLC power stage, respectively, in a
step 620. - In a
step 630, the first and second power inputs are actively adjusted to substantially match output voltage and current levels for a given load condition and a common operating frequency between the first and the second LLC power stages. In one embodiment, the first and second power inputs are modulated to obtain the substantial match. The first and second DC power outputs are interleaved in astep 640. Themethod 600 then ends in astep 650. - Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments. Additionally, one skilled in the art will understand that conventional components such as sensors may be used to sense the various currents and voltages that are employed by the various disclosed LLC converters.
- Portions of the above-described apparatuses and methods may be embodied in or performed by various digital data processors or computers, wherein the computers are programmed or store executable programs of sequences of software instructions to perform one or more of the steps of the methods e.g., a step or steps of the methods or processes of
FIG. 6 . The software instructions of such programs may represent algorithms and be encoded in machine-executable form on conventional digital data storage media, e.g., magnetic or optical disks, random-access memory (RAM), magnetic hard disks, flash memories, and/or read-only memory (ROM), to enable various types of digital data processors or computers to perform one, multiple or all of the steps of one or more of the above-described methods. Accordingly, computer storage products with a computer-readable medium, such as a non-transitory computer-readable medium, that have program code thereon for performing various computer-implemented operations that embody the tools or carry out the steps of the methods set forth herein may be employed. A non-transitory media includes all computer-readable media except for a transitory, propagating signal. The media and program code may be specially designed and constructed for the purposes of the disclosure, or they may be of the kind well known and available to those having skill in the computer software arts. An apparatus may be designed to include the necessary circuitry or series of operating instructions to perform a step or steps of the disclosed methods
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US13/218,938 US9083242B2 (en) | 2010-12-17 | 2011-08-26 | Interleaved LLC converter employing active balancing |
CN201110293979.2A CN102545596B (en) | 2010-12-17 | 2011-09-28 | Utilize the alternating expression LLC converter of active balance |
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US13/218,938 US9083242B2 (en) | 2010-12-17 | 2011-08-26 | Interleaved LLC converter employing active balancing |
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US9083242B2 (en) | 2015-07-14 |
CN102545596B (en) | 2015-10-21 |
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